Method for producing ceramic honeycomb structure

Abstract

A method for producing a ceramic honeycomb structure comprising aluminum titanate as a main crystal, comprising the steps of mixing titania powder, alumina powder and amorphous silica powder, the molar ratio of the titania powder to the alumina powder being 45:55 to 55:45, the amount of the amorphous silica powder being 1-10 parts by mass per 100 parts by mass of the total of the titania powder and the alumina powder, to produce a moldable material; extruding said moldable material in a honeycomb shape; drying it; and then sintering it at 1300-1700° C.

What is claimed is: 
     
       1. A method for producing a ceramic honeycomb structure comprising aluminum titanate as a main crystal, comprising the steps of
 mixing 
 ceramic powder consisting of titania powder, alumina powder and amorphous silica powder having a purity of 99.5% or more, the molar ratio of the titania powder to the alumina powder being 48:52 to 52:48, the amount of the amorphous silica powder being 2-6 parts by mass per 100 parts by mass of the total of the titania powder and the alumina powder, 
 a binder, 
 a single pore-forming material, and 
 water, to produce a moldable material; 
 extruding said moldable material in a honeycomb shape; 
 drying said moldable material in a honeycomb shape; and then 
 sintering said moldable material in a honeycomb shape at 1400-1700° C., 
 wherein said single pore-forming material consists of one item selected from the group consisting of wheat powder, graphite, and foamed resin particles. 
 
     
     
       2. The method for producing a ceramic honeycomb structure according to  claim 1 , wherein amorphous silica powder is composed of molten silica obtained by melting silica stone. 
     
     
       3. The method for producing a ceramic honeycomb structure according to  claim 1 , wherein said amorphous silica powder has an average particle size of 2-30 μm. 
     
     
       4. The method for producing a ceramic honeycomb structure according to  claim 1 , wherein said amorphous silica powder has an aspect ratio of 1-7. 
     
     
       5. The method for producing a ceramic honeycomb structure according  claim 1 , wherein said titania powder has an average particle size of 0.05-3 μm. 
     
     
       6. The method for producing a ceramic honeycomb structure according to  claim 1 , wherein said alumina powder has an average particle size of 0.1-5 μm.